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Abstract:

An odorless composite floor tile suitable for indoor or outdoor use is
formed from elastomer particles. The composite floor tile has a lower
layer that is formed by binding a first group of elastomer particles with
an adhesive, and is stabilized with meshes of fiberglass fibers. The
composite floor tile also has a laminated upper layer. The laminated
upper layer is formed by binding a second group of elastomer particles
with the adhesive, or formed from synthetic rubber and/or natural rubber,
polymeric materials, or fiber materials. The composite floor tile has
shock absorption and anti-slippage properties. The composite floor tile
has an attractive upper surface that includes a variety of color
patterns. Further, the composite floor tile also has a shock absorbing
lower layer providing an air cushion effect that is also permeable to air
and liquids which reduces or eliminates the breeding and spread of
bacteria and mildew.

Claims:

1. A composite floor tile, comprising: a lower layer that includes a
first plurality of elastomer particles that are bound together by an
adhesive; and a laminated upper layer attached to the lower layer that is
formed from a second plurality of elastomer particles that are bound
together by the adhesive, a polymeric material, or a fiber material.

2. The composite floor tile of claim 1, wherein the lower layer and the
laminated upper layer are joined by the adhesive.

3. The composite floor tile of claim 1, wherein each of the first
plurality of elastomer particles and the second plurality of elastomer
particles include multi-colored elastomer particles.

4. The composite floor tile of claim 1, wherein the first plurality of
elastomer particles are of a first number of colors and the second
plurality of elastomer particles are of a second number of colors that is
less than or greater than the first number of colors.

5. The composite floor tile of claim 1, wherein the adhesive is a
polyurethane-based adhesive.

6. The composite floor tile of claim 4, wherein the laminated upper layer
forms a rubber sheet with a density that is 25% to 40% higher than a
density of the lower layer.

7. The composite floor tile of claim 1, wherein the lower layer includes
at least one protrusion or at least one cavity facing away from the
laminated upper layer.

8. The composite floor tile of claim 1, wherein the lower layer includes
one or more air chambers that provides shock absorption via an air
cushion effect, one or more embedded mesh sheets of fiberglass fibers
that provide stability to the first plurality of the elastomer particles
of the lower layer, or a combination thereof.

9. The composite floor tile of claim 1, wherein the second plurality of
elastomers include elastomer particles of a primary color that form a
background color of the laminated upper layer, and groups of elastomer
particles of one or more secondary colors that are intermixed with the
elastomer particles of the primary color.

10. A method, comprising: binding a plurality of elastomer particles with
an adhesive to form a lower layer having multiple colors; forming a
laminated upper layer having a primary background color and one or more
secondary colors that are dispersed throughout the primary background
color; and joining the lower layer and the laminated upper layer to form
a composite floor tile.

11. The method of claim 10, wherein the forming includes forming the
laminated upper layer from an additional plurality of elastomer particles
that are bound with the adhesive, forming the laminated upper layer from
a polymeric material, or forming the laminated upper layer from a fiber
material.

12. The method of claim 11, wherein the elastomer particles are synthetic
rubber natural rubber, or a combination thereof, the polymeric material
is one of polyvinyl chloride (PVC), polyethylene (PE), polypropylene
(PP), polyurethane (PU) composite, or plastic cement, and the fiber
material is one of carpet or khaki.

13. The method of claim 10, wherein the binding the plurality of
elastomer particles includes forming a lower layer that includes at least
one protrusion or at least one cavity.

14. The method of claim 10, wherein the binding the plurality of
elastomer particles includes embedding one or more mesh sheets of
fiberglass fibers in the plurality of elastomer particles.

15. The method of claim 10, wherein the binding the plurality of
elastomer particles includes forming one or more air chambers in the
lower layer that provide an air cushioning effect.

16. The method of claim 11, wherein the binding the plurality of
elastomer particles or the binding the additional plurality of elastomer
particles includes curing the adhesive using at least one of a
temperature that is higher than an ambient room temperature or a pressure
that is higher than one standard atmosphere.

17. A method, comprising: binding a first plurality of elastomer
particles with an adhesive to form a lower layer of a first density;
binding a second plurality of elastomer particles with the adhesive to
form a laminated upper layer of a second density that is greater than the
first density; and joining the lower layer and the laminated upper layer
to form a composite floor tile.

18. The method of claim 17, wherein the binding the first plurality of
elastomer particles further comprises; placing a layer of elastomer
particles of the first plurality of elastomer particles and the adhesive
into a mold; positioning one or more removable inserts in the mold;
covering the removable inserts with an additional layer of elastomer
particles of the first plurality of elastomer particles and the adhesive;
curing the adhesive to bind the first plurality of elastomer particles
into the lower layer; removing the removable inserts from the mold; and
removing the lower layer from the mold.

19. The method of claim 17, wherein the binding the first plurality of
elastomer particles further comprises: placing a layer of elastomer
particles of the first plurality of elastomer particles and the adhesive
into a mold; positioning a mesh sheet of fiberglass fibers on the layer
of elastomer particles; covering the mesh sheet with an additional layer
of elastomer particles of the first plurality of elastomer particles and
the adhesive; curing the adhesive to bind the first plurality of
elastomer particles into the lower layer; and removing the lower layer
from the mold.

20. The method of claim 17, wherein the laminated upper layer formed by
the binding of the first plurality of elastomer particles has less color
variation or more color variation than the lower layer formed by the
binding of the second plurality of elastomer particles.

Description:

TECHNICAL FIELD

[0001] This invention relates to systems and methods for flooring, and
more specifically, to systems and methods for providing durable, shock
absorbing, anti-slippage, and colorful floor surfaces.

BACKGROUND

[0002] Durable floor surfaces that provide good shock absorption and
anti-slippage properties are more and more popular, and are used in a
variety of application. Such floors may be used in gyms, playgrounds,
senior activity centers, as well as other indoor or outdoor facilities
where safety is a concern. However, conventional flooring materials that
provide such shock absorption and anti-slippage properties often have low
density face layers that are porous to the environment, so that such
conventional floor materials may be easily worn out and have short
service lives. Further, such conventional floor may readily accumulate
dirt, mold, and bacteria. The accumulation of dirt, mold, and bacteria
may result in unhealthy environments at the facilities where such
conventional floor materials are used, and may contribute to the spread
of diseases and illnesses at these facilities. Therefore, it would be
advantageous to have a floor material that does not have the one or more
shortcoming described above.

SUMMARY

[0003] Described herein are systems and methods for providing a composite
floor tile that has shock absorption and anti-slippage properties. The
composite floor tile has an attractive laminated upper layer that
includes a variety of fade-resistant color patterns. The attractive
laminated upper layer may be formed from various materials, including
elastomers such as natural or synthetic rubber, polymers such as plastic
cement, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP),
polyurethane (PU) composite, and/or other plastics, and fabric such as
carpet, or other clothing material (such as khaki). The composite floor
tile has anti-mildew and anti-bacteria properties, and is odorless. Thus,
compare to conventional floor tiles with dyed colors, the composite floor
described herein is more suitable for outdoor use than conventional floor
tiles. Nevertheless, the odorless characteristic of the composite floor
also makes it especially suitable for indoor use as well.

[0004] Further, the composite floor tile also has a shock absorbing lower
layer that is joined to the upper layer. The shock absorbing lower layer
provides an air cushion effect, The shock absorbing lower layer is also
permeable to air and liquids, which reduces or eliminates the breeding
and spread of bacteria. The shock absorbing lower layer may have a lower
density than the laminated upper layer, in which the upper layer may be
formed as a high density rubber sheet with a density 25% to 40% higher
than the density of the lower layer. In various embodiments, the lower
layer of the composite floor tile is formed by binding a first group of
elastomer particles with an adhesive. In some embodiments, the lower
layer of the composite floor tile is reinforced with one or more mesh
sheets, such as mesh sheets of fiberglass fibers, which provide strength
and stabilize the composite floor tile in different environments. The
laminated upper layer of the composite floor tile is formed by binding a
second group of elastomer particles with the adhesive, formed from a
polymeric material, or formed from a fabric material.

[0005] In other embodiments, a multi-colored lower layer of the composite
floor tile is formed by binding together a first group of elastomer
particles with an adhesive. A laminated upper layer of the composite
floor tile is formed by binding together a second group of elastomer
particles with the adhesive formed from a polymeric material, or formed
from a fabric material. The laminated upper layer is formed to present a
primary background color and one or more secondary colors that are
dispersed throughout the primary background color. The composite floor
tile is formed by joining the lower layer with the laminated upper layer.

[0006] In additional embodiments, a lower layer of one density is formed
by binding a first group of elastomer particles with an adhesive. A
laminated upper layer of another density is formed by binding a second
group of elastomer particles with an adhesive. The density of the
laminated upper layer is greater than the density of the lower layer. The
composite floor tile is formed by joining the lower layer with the
laminated upper layer.

[0007] Thus, the composite floor tile in accordance with the embodiments
has exceptional durability, comfort, resilience, density, and stability
characteristics. The composite floor tile also exhibits outstanding
performance and longevity in multiple environments, such as being
slip-resistance even when wet. The composite floor tile provides an
environmentally-friendly floor solution that is also easy to install and
maintain, and may be used to control the spread of bacteria and dust.

[0008] The features, functions, and advantages that have been discussed
above or will be discussed below can be achieved independently in various
embodiments, or may be combined in yet other embodiments, further details
of which can be seen with reference to the following description and
drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Embodiments in accordance with the teachings of the present
disclosure are described in detail below with reference to the following
drawings.

[0010] FIG. 1 is an isometric view of an exemplary composite floor tile in
accordance with various embodiments;

[0011]FIG. 2 is a top view of an exemplary composite floor tile in
accordance with various embodiments;

[0012]FIG. 3 is a bottom view of an exemplary composite floor tile with
lower surface protrusions in accordance with various embodiments;

[0013]FIG. 4 is a side view of an exemplary composite floor tile with
lower surface protrusions in accordance with various embodiments;

[0014]FIG. 5 is a bottom view of an exemplary composite floor tile with
lower surface cavities in accordance with various embodiments;

[0015]FIG. 6 is an isometric view of an exemplary mold that is used to
form a lower layer of the composite floor tile, in accordance with
various embodiments.

[0016]FIG. 7 is a flow diagram illustrating an exemplary process for
forming the exemplary composite floor tiles shown in FIGS. 1-5, in
accordance with various embodiments.

[0017]FIG. 8 is a flow diagram illustrating an exemplary process for
forming a lower layer of an exemplar floor composite floor tile that is
provided with one or more air chambers, in accordance with various
embodiments.

[0018]FIG. 9 is a flow diagram illustrating an exemplary process for
forming a lower layer of an exemplary composite floor tile that is
reinforced with one or more mesh sheets, in accordance with various
embodiments.

DETAILED DESCRIPTION

[0019] Described herein are embodiments of a composite floor tile that has
shock absorption anti-slippage properties. The composite floor tile
include a laminated upper layer that may be from various materials,
including elastomers such as natural or synthetic rubber, polymers such
as plastic cement, polyvinyl chloride (PVC), polyethylene (PE),
polypropylene (PP), polyurethane (PU) composite, and/or other plastics,
and fabric such as carpet or other clothing materials, such as khaki. In
some embodiments, the laminated upper layer is impermeable or virtually
impermeable to dirt, liquids, or other particulate matter. The composite
floor tile further includes a shock absorbing lower layer of bound
elastomeric particles that is reinforced with one or more mesh sheets,
such as mesh sheets of fiberglass fibers, which provide strength and
stabilize the composite floor tile in different environment. The shocking
absorbing lower layer may have a lower density than the laminated upper
layer. In at least one embodiment, the upper layer may be formed as a
high density rubber sheet with a density 25% to 40% higher than the
density of the lower layer. Thus, in many instances, the composite floor
tile may reduce the spread of harmful contaminants during use, while
providing an air cushion effect that simultaneously protect personnel or
properties from vibrations, shocks, and falls. In some embodiments, the
composite floor tile also provides an attractive fade-resistant upper
surface that includes a variety of pleasing color patterns, thereby
enhancing the aesthetics of the surrounding environments.

[0020] Thus, the composite floor tile in accordance with the embodiments
has exceptional durability, comfort, resilience, density, and stability
characteristics. The composite floor tile also exhibits outstanding
performance and longevity in multiple environments, such as being
slip-resistance even when wet. The composite floor tile provides an
environmentally-friendly floor solution that is also easy to install and
maintain, and may be used to control the spread of bacteria, mildew and
dust. Further, the composite floor tile is odorless. Thus, compare to
conventional floor tiles with dyed colors, the composite floor described
herein is more suitable for outdoor use than conventional floor tiles.
Nevertheless, the odorless characteristic of the composite floor tile
described herein also makes it especially suitable for indoor use as
well.

[0021] Many specific details of certain embodiments are set forth in the
following description and in FIGS. 1-6 to provide a thorough
understanding of such embodiments. The present disclosure may have
additional embodiments, or may be practiced without one or more of the
details described below.

[0022] FIG. 1 is an isometric view of an exemplary composite floor tile
102 in accordance with various embodiments. The exemplary composite floor
tile 102 includes a lower layer 104 and a laminated upper layer 106. The
lower layer 104 may include a plurality of discrete elastomer particles
108 that are bind together with an adhesive. For the purpose of
illustration, the proportions of the elastomer particles 108 with respect
to the overall dimensions of the composite floor tile 102 are
exaggerated. In at least some actual embodiments, each of the elastomer
particles 108 may range from 0.2 mm to 0.4 mm in cross-sectional length.
The elastomer particles 108 may include natural elastomer particles
(e.g., particles that are made from natural rubber or latex), synthetic
elastomer particles (e.g., particles that are made from butyl rubber,
styrene-butadiene rubber, ethylene propylene rubber, etc.), or a
combination of natural and synthetic elastomer particles.

[0023] The elastomer particles 108 may be derived from a variety of
sources. In some instances, the elastomer particles 108 may be
manufactured from recycled rubber products, such as discarded rubber
insoles, rubber shoes, rubber boots, and so forth. In such instances, the
recycled rubber products may be shredded into uniform-sized or near
uniform sized particles to form the elastomer particles 108. In
alternative instances, the elastomer particles 108 may be manufactured
from new natural or synthetic elastomers. However, in additional
instances, the elastomer particles 108 may include both recycled and
newly manufactured elastomer particles.

[0024] In some embodiments, the elastomer particles 108 that are used to
form the lower layer 104 may have the same density or substantially the
same density. However, in other embodiments, the elastomer particles 108
may include particles of different density so long as the overall density
of the lower layer 104 that is manufactured from the elastomer particles
108 achieves the desired density.

[0025] The elastomer particles 108 are bound together with an adhesive to
form the lower layer 104. In some embodiments, the adhesive may be a
polyurethane-based adhesive. However, any elastomer binding adhesive may
be used to bind the elastomer particles 108 into the lower layer 104 in
other embodiments. The binding of the elastomer particles 108 with the
adhesive into the lower layer 104 may be achieved with the use of a mold.
The binding of the elastomer particles 108 with the adhesive may be
performed under high temperature and/or high pressure. For example, the
adhesive may be cured using a temperature that is higher than the normal
room temperature range of 20° C.-25° C. Concurrently or
alternatively, the adhesive curing may be achieved when elastomer
particles 108 are under a pressure that is higher than one standard
atmosphere (1 atm), or 760 Torr. Such pressure may be achieved via the
use of a pressure mold that exerts compressive force on every surface of
the lower layer 104 being formed.

[0026] In some embodiments, the lower layer 104 may be provided with one
or more air chambers 110. Each of the air chambers 110 may extend through
at least a portion of the lower layer 104 or the entire length of the
lower layer 104. Multiple air chambers 110 may be regularly spaced apart
in the lower layer 104. As further described below, each of the air
chambers may be formed with the insertion of a removable insert during
the molding of the elastomer particles 108 with adhesive into the lower
layer 104. Thus, upon the removal of a removable insert after curing of
the adhesive, a corresponding air chamber 110 is created in the lower
layer 104. The air chambers 110 may improve the shock absorption
properties of the composite floor tile 102 in the same manner that air
pockets in the sole of an athletic shoe cushion a foot from ground
impact. Each of the air chambers 110 may have any number of
cross-sectional shapes (e.g., circular, oval, square, rectangular, etc.).

[0027] In other embodiments, the lower layer 104 is reinforced with one or
more mesh sheets 112 that are embedded in the elastomer particles 108 of
the lower layer 104. Each of the mesh sheets 112 may include an
interwoven matrix of fiber material that has substantially the same or
smaller surface dimensions as the lower layer 104 being made. In various
embodiments, the interwoven matrix of fiber material may include
fiberglass fibers, carbon fibers, and/or polymer fibers. The
reinforcement of the lower layer 104 with the one or more mesh sheets
112, such as the fiberglass fibers, may counteract the natural tendency
of the elastomer particles 108 to expand and contract in different
temperatures, and stabilize the composite floor tile 102 in different
environments. For example, a composite floor tile 102 with a lower layer
104 that is reinforced with the mesh sheets 112 may be suited for use in
open air facilities, such as public parks, playgrounds, stadiums, etc.

[0028] The one or more mesh sheets 112 are embedded into the lower layer
104 during the molding of the lower layer 104 from elastomer particles
108 and the adhesive. The actual number of the mesh sheets 112 that are
embedded into the lower layer 104 may be dependent on the desired
thickness of the lower layer 104, which may be based on the overall
desired thickness of the composite tile 102. For example, a greater
number of mesh sheets 112 may be placed into a thicker lower layer 104
than placed into a thinner lower layer 104 in order to achieve the same
degree of stability.

[0029] In various embodiments, the laminated upper layer 106 may include a
plurality of discrete elastomer particles 114 that are also bind together
with the elastomer binding adhesive described above. For the purpose of
illustration, the proportions of the elastomer particles 114 with respect
to the overall dimensions of the composite floor tile 102 are
exaggerated. In at least some actual embodiments, each of the elastomer
particles 114 may range from 0.2 mm to 0.4 mm in cross-sectional length.
The elastomer particles 114 may also include natural elastomer particles,
synthetic elastomer particles, or a combination of natural and synthetic
elastomer particles from recycled and/or new production sources. The
elastomer particles 114 may also be bind together with the elastomer
binding adhesive at the temperature and/or the pressure described above
during manufacturing. The pressure may be achieved via the use of a
pressure mold that exerts compressive force on every surface of the
laminated upper layer 106.

[0030] In some embodiments, the elastomer particles 114 that are used to
form the laminated upper layer 106 may have the same density or
substantially the same density. However, in other embodiments, the
elastomer particles 114 may include particles of different density so
long as the overall density of the laminated upper layer 106 that is
manufactured from the elastomer particles 114 achieves the desired
density. The laminated upper layer 106 may be formed by binding the
elastomer particles 114 with adhesive in a mold. The binding of the
elastomer particles 114 with the adhesive may be performed under high
temperature and/or high pressure. For example, the adhesive may be cured
using a temperature that is higher than the normal room temperature range
of 20° C.-25° C. Concurrently or alternatively, the
adhesive curing may be achieved when elastomer particles 114 are under a
pressure that is higher than one standard atmosphere (1 atm), or 760
Torr. Such pressure may be achieved via the use of a pressure mold that
exerts compressive force on every surface of the laminated upper layer
106 being formed. In some embodiments, the production of the laminated
upper layer 106 may also include cutting the formed laminated upper layer
106 to match the surface dimensions of the previously formed lower layer
104.

[0031] The lower layer 104 and the laminated upper layer 106 may be joined
together with an elastomer binding adhesive, such as the
polyurethane-based adhesive, that is disposed between the lower layer 104
and the laminated upper layer 106 to form the composite floor tile 102.
In this way, the laminated upper layer 106 provides an upper surface 116
for the composite floor tile 102, and the lower layer 104 provides a
lower surface 118 for the tile. The lower layer 104 and the laminated
upper layer 106 may also be joined together with the adhesive at a high
temperature and/or high pressure. For example, the adhesive may be cured
using a temperature that is higher than the normal room temperature range
of 20° C.-25° C. Concurrently or alternatively, the
adhesive curing may be achieved when elastomer particles 108 are under a
pressure that is higher than 1 atm.

[0032] In some embodiments, the composite floor tile 102 may be formed so
that the overall density of the laminated upper layer 106 may be higher
than the overall density of the lower layer 104. For example, in at least
one embodiment, the density of the lower layer 104 may be 600 kg/m3,
while the density of the laminated upper layer 106 may be 700 kg/m3.
In other embodiments, the laminated upper layer 106 may be formed as a
high-density rubber sheet of synthetic rubber and/or natural rubber with
a density that is 25% to 40% denser than the density of the lower layer
104. Further, the lower layer 104 may be formed so that it is thicker
than the laminated upper layer 106. For example, in at least one other
embodiment, the thickness of the laminated upper layer 106 may be 0.5-2.0
mm, while the thickness of the lower layer may be 18 mm. In such
embodiments, the overall thickness of the composite floor tile 102 may be
between 12-110 mm.

[0033] Thus, the difference in the densities and/or the difference in the
thickness of the lower layer 104 and the laminated upper layer 106 may
produce a composite floor tile 102 that possesses both favorable shock
absorption and contaminant impermeability characteristics. For example,
the thicker and lower density lower layer 104 may absorb shocks and
vibrations, while the thinner and higher density laminated upper layer
106 may be less porous than the lower layer 104 to reduce or eliminate
the penetration of dirt, liquids, or other particulate matter into the
upper surface 116 of the composite floor tile 102 during use. As a
result, the growth of mold, mildew, or bacteria on the upper surface 116
may be reduced or eliminated. The thinner and higher density laminated
upper layer 106 may also enable the composite floor tile to provide a
uniform and smooth deformation-resistant surface that also eliminates or
reduces slip and fall hazards. Nevertheless, it will be appreciated that
the thickness of the lower layer 104 and the laminated upper layer 106
may vary in other embodiments. For example, the thickness of the lower
layer 104 may be equal to or less than the thickness of the laminated
upper layer 106. Even with such variations in the lower layer 104 and the
laminated upper layer 106, the density of the laminated upper layer 106
may still be higher than the density of comparable layers in conventional
floor tiles. Accordingly, the composite tile 102 may offer superior
durability and anti-slippage properties than conventional floor tiles.

[0034] As described above, the elastomer particles for forming the
composite floor tile 102 may be recycled products. Accordingly, the
source elastomer particles for the elastomer particles 108 and the
elastomer particles 114 may be multi-colored elastomer particles.
However, in order to achieve an aesthetically pleasing composite floor
tile 102, elastomer particles 114 of a single color may be used to form
the laminated upper layer 106.

[0035] Nevertheless, in other embodiments, the colors of elastomer
particles 114 may be selected and blended so that elastomer particles 114
of a particular color predominates in the resultant laminated upper layer
106, while elastomer particles 114 of a predetermined number of colors
(e.g., 1-3 colors) are intermixed with the elastomer particles 114 of the
predominate color. For example, the laminated upper layer 106 may be
formed from predominately black elastomer particles, with some groups of
white and yellow elastomer particles intermixed among the black elastomer
particles. In this way, the resultant color pattern of the laminated
upper layer 106 may have a "night sky" appearance that is both colorful
and pleasing to the eye. Thus, since there may be potentially tens of
thousands of color designs available, the resulting composite tile 102
may be much more visually appealing than conventional single-color floor
tiles.

[0036] In contrast, the lower layer 104 is generally not visible when the
composite floor tile 102 is installed. As such, the elastomer particles
108 may be elastomer particles of any color blend that is obtained from
any source. Accordingly, in at least some embodiments, the elastomer
particles 114 that form the laminated upper layer 106 may contain less
color variation than the elastomer particles 108 that form the lower
layer 104.

[0037] However, in other embodiments, the elastomer particles 114 that
form the laminated upper layer 106 may contain more color variation than
the elastomer particles 108 that form the lower layer 104. In other
words, the laminated upper layer 106 that is formed by the elastomer
particles 114 may have a greater number of colors than the lower layer
104 that is formed from by the elastomer particles 108. Such embodiments
may suit a different aesthetic taste with respect to color patterns for
the composite floor tile 102.

[0038] In some alternative embodiments, the laminated upper layer 106 is
formed from a polymeric material, such polyvinyl chloride (PVC),
polycarbonate (PC), polyethylene (PE), plastic cement, polypropylene
(PP), and/or other plastics, or from polyurethane (PU) composite. The
polymeric material in a laminated upper layer 106 may be of a uniform
color, or include polymer particles of different colors that are fused
together to produce a variety of different colors in a similar manner as
the elastomer particles 114. In other alternative embodiments, the
laminated upper layer 106 is formed from natural fabric materials (e.g.,
wool, cotton, etc), synthetic fabric materials (e.g., polypropylene,
fiberglass, etc.), or a blend of natural and synthetic fiber materials.
For example, the laminated upper layer 106 may be formed from textile in
the form of carpet that includes a layer of pile, textile in the form of
khaki, and/or other woven fabric clothing material. The synthetic and/or
natural fabric in the laminated upper layer 106 may includes fabric
strands of different colors or a uniform color. Accordingly, the fabric
may be woven into a uniform color, or woven into different color patterns
and different designs. For example, a laminated upper layer 106 formed
from the synthetic and/or natural fabric may exhibit similar color
variations and designs as a laminated upper layer 106 that is formed from
the elastomer particles 114.

[0039] In such embodiments, the lower layer 104 and the laminated upper
layer 106 may also be joined together with a suitable binding adhesive
that is disposed between the lower layer 104 and the laminated upper
layer 106 to form the composite floor tile 102.

[0040]FIG. 2 is a top view of the exemplary composite floor tile 102 in
accordance with various embodiments. As shown, the upper surface 116 of
the composite floor tile 102 is a surface of the laminated upper layer
106. In some embodiments, the upper surface 116 may include a background
202 that is made up of elastomer particles of a predomination color
(e.g., black). Groups of elastomer particles of a first color (e.g.,
white), such as an elastomer particles 204, and groups of elastomer
particles of a second color (e.g., yellow), such as an elastomer
particles 206, are dispersed throughout the background 202. In other
embodiments, the upper surface 106 may be formed from polymers or fabrics
that exhibit similar designs as formed by the elastomer particles 204 and
206, as well as other designs and patterns.

[0041] As further shown, the composite floor tile 102 may be a square tile
in at least one embodiment. For example, the composite floor tile 102 may
have a width of 50 cm and a length of 50 cm. Nevertheless, the composite
floor tile 102 may be of any shape (e.g., rectangle, triangle, hexagon)
and any dimension (e.g., 40 cm by 60 cm) in other embodiments provided
that multiples of the composite floor tile 102 of a single shape, or a
combination of shapes, may be fitted together to cover a surface without
leaving any holes.

[0042]FIG. 3 is a bottom view of an exemplary composite floor tile 302
with lower surface protrusions in accordance with various embodiments.
The composite floor tile 302 may be manufactured using the same materials
and techniques as the composite floor tile 102. However, the composite
floor tile 302 may include protrusions on a lower layer 304. The lower
layer 304 may be similar to the lower layer 104 of the composite floor
tile 102. The protrusions may be formed by pressing a portion of a
pressure mold with a negative impression of the protrusions against a
surface of the lower layer 34 during the binding of the elastomer
particles 108 with the elastomer binding adhesive. The protrusions may be
in the form of circular studs, such as circular stud 306 and perimeter
tabs, such as the perimeter tab 308. Thus, when the composite floor tile
302 is positioned on top of an underlying substrate (e.g., subfloor), the
protrusions may enhance the grip ability of the composite floor tile 302
against the underlying substrate by providing edges that resist slippage
of the composite floor tile 302 on the underlying substrate.
Additionally, the protrusions may also promote the circulation of air
underneath the composite floor tile 302, thereby reducing the
accumulation of moisture that may contribute to mold or bacterial growth.
It will be appreciated that while a particular pattern of the surface
protrusions (e.g., a combination of circular studs 306 and perimeter tabs
308) is shown in FIG. 3, other patterns of protrusions may be implemented
for the composite floor tile 302 in additional embodiments. These
protrusion patterns may be implemented so long as the protrusion patterns
do not affect the stability or the deformation-resistance of the
composite floor tile 302.

[0043]FIG. 4 is a side view of the exemplary composite floor tile 302
with lower surface protrusions in accordance with various embodiments. As
shown, the protrusions 402 may form recesses 404 underneath the composite
floor tile 302 when the tile is placed on the underlying substrate (e.g.,
subfloor). As described above, the protrusions 402 may enhance the
slippage-resistance of the composite floor tile 302 against the
underlying substrate. The recesses 404 may promote air circulation
underneath the composite floor tile 302.

[0044]FIG. 5 is a bottom view of an exemplary composite floor tile 502
with lower surface cavities in accordance with various embodiments. The
composite floor tile 502 may be manufactured using the same materials and
techniques as the composite floor tile 102. However, the composite floor
tile 502 may include cavities, such as the cavity 504, which at least
partially penetrate into a lower layer 506 of the composite floor tile
502. The lower layer 506 may be similar to the lower layer 104 of the
composite floor tile 102. The cavities on the lower layer 506 may be
formed by pressing a portion of a pressure mold with a positive
impression of the lower surface cavities against a surface of the lower
layer 506 during the binding of the elastomer particles 108 with the
elastomer binding adhesive.

[0045] Thus, when the composite floor tile 502 is positioned on top of an
underlying substrate (e.g., subfloor), the lower surface cavities may
enhance the grip ability of the composite floor tile 502 against the
underlying substrate by providing edges that resist slippage of the
composite floor tile 502 on the underlying substrate. Additionally, the
cavities may reduce the weight of the composite floor tile 502 without
affecting the structural strength of the composite floor tile 502. The
reduced weight of the composite floor tile 502 may make it easier to
install or remove the composite floor tile 502.

[0046] It will be appreciated that while a particular honeycombed box
pattern of the cavities is shown in FIG. 5, other patterns of cavities
may be implemented for the composite floor tile 502 in additional
embodiments. These cavity patterns may be implemented so long as the
patterns do not affect the structural rigidity or the
deformation-resistance of the composite floor tile 502.

[0047]FIG. 6 is an isometric view of an exemplary mold 600 that is used
to form a lower layer of a composite floor tile, in accordance with
various embodiments. For the sake of illustration clarity, a front side
and a top cover of the mold 600 are not shown in FIG. 6. Elastomer
particles 108 and an adhesive may be placed in the mold 600 to form a
lower layer of a composite floor tile, such as the lower layer 104. The
mold 600 includes one or more projections 602 on its bottom side 604. The
projections 602 may form one or more projections patterns. The one or
more projections are used to produce the one or more protrusions (e.g.,
protrusions 402) and/or one or more cavities (e.g., cavity 504) that are
present on the lower surface 118 of the lower layer 104.

[0048] The mold 600 also includes one or more side openings 606 that
receive corresponding removable inserts 608. As shown, each of the one or
more removable inserts 608 may be a cylindrical rod that is inserted into
the mold 600 during the placement of the elastomer particles 108 and an
adhesive into the mold 600. Accordingly, upon curing of the adhesive, the
removable inserts 608 are removed to form the air chambers 110. Further,
one or more mesh sheet 112 may be embedded in the elastomer particles 108
that are placed into the mold 600 prior to the insertion of at least some
of the removable inserts 608. Alternatively, one or more mesh sheets 112
may be embedded in the elastomer particles 108 before or following the
placement of all the removable inserts 608 in the elastomer particles 108
for forming the air chambers 110.

[0049] FIGS. 7-9 are flow diagrams that illustrate exemplary processes
related to the formation of the exemplary floor tiles shown in FIGS. 1-5.
The order in which the operations are described in each of the figures is
not intended to be construed as a limitation, and any number of the
described blocks can be combined in any order and/or in parallel to
implement the process.

[0050]FIG. 7 is a flow diagram illustrating an exemplary process 700 for
forming the exemplary composite floor tiles shown in FIGS. 1-5, in
accordance with an embodiment.

[0051] At block 702, a group of the elastomer particles 108 are bind
together to form a lower layer, such as the lower layer 104. In various
embodiments, the elastomer particles 108 may include natural elastomer
particles, synthetic elastomer particles, or a combination of natural and
synthetic elastomer particles from recycled and/or new production
sources. In some embodiments, the elastomer particles 108 may be bind
together with an elastomer binding adhesive at a temperature that is
higher than a normal room temperature range and/or a pressure that is
higher than 1 atm. In some embodiments, a pressure mold with a positive
or negative impression may be used to respectively provide the lower
layer 104 with at least one protrusion or at least one cavity at a
surface of the lower layer 104. In some embodiments, the formed lower
layer may be provided with the one or more air chambers 110 and/or
reinforced with the one or more mesh sheets 112.

[0052] At block 704, a laminated upper layer is formed. In some
embodiments, another group of the elastomer particles 114 are bind
together to form a laminated upper layer, such as the laminated upper
layer 106. In various embodiments, the elastomer particles 114 may
include natural elastomer particles, synthetic elastomer, or a
combination of natural and synthetic elastomer particles from recycled
and/or new production sources. In some embodiments, the elastomer
particles 114 may be bind together with an elastomer binding adhesive at
a temperature that is higher than a normal room temperature range and/or
a pressure that is higher than 1 atm. The laminated upper layer 106 that
is formed from the elastomer particles 114 may have a higher density than
the lower layer 104 that is formed from the elastomer particles 108. In
at least one embodiment, the laminated upper layer 106 may be formed as a
high-density rubber sheet of synthetic rubber and/or natural rubber with
a density that is 25% to 40% denser than the density of the lower layer
104. Further, the elastomer particles 114 that form the laminated upper
layer 106 may contain less color variation or more color variation than
the elastomer particles 108 that form the lower layer 104.

[0053] In other embodiments, the laminated upper layer 106 is formed from
a polymeric material, such polyvinyl chloride (PVC), polycarbonate (PC),
polyethylene (PE), plastic cement, polypropylene (PP), and/or other
plastics, or from polyurethane (PU) composite. In additional embodiments,
the laminated upper layer 106 is formed from natural fiber materials
(e.g., wool, cotton, etc), synthetic fiber materials (e.g.,
polypropylene, fiberglass, etc.), or a blend of natural and synthetic
fiber materials. For example, the laminated upper layer 106 may be formed
from textile in the form of carpet that includes a layer of pile, denim,
khaki, and/or other woven fabric clothing material. The laminated upper
layer 106 that is formed from the polymeric material or the fiber
material may contain less color variation or more color variation than
the lower layer 104 that is formed from the elastomer particles 108.

[0054] At block 706, the lower layer 104 and the laminated upper layer 106
are bound together to form a composite floor tile, such as the composite
floor tile 102. In various embodiments, the lower layer 104 and the
laminated upper layer 106 are joined together with an elastomer binding
adhesive at a temperature that is higher than a normal room temperature
range and/or a pressure that is higher than 1 atm. The resulting
composite floor tile may include an upper surface, such as the upper
surface 116, which is form by a surface of the laminated upper layer 106.
The resulting composite floor tile 102 may also include a lower surface,
such as the lower surface 118, which is formed by a surface of the lower
layer 104. In some embodiments, rather than a smooth and uniform lower
surface 118, the lower surface 118 of the composite floor tile 102 may
include at least one protrusion or at least one cavity.

[0055]FIG. 8 is a flow diagram illustrating an exemplary process 800 for
forming a lower layer 104 of the composite floor tile 102 that is
provided with one or more air chambers, in accordance with various
embodiments. The exemplary process 800 further illustrates block 702 of
the process 700. Further, at least some operations of the process 800 may
be implemented concurrently with the exemplary process 900 described
below.

[0056] At block 802, a layer of elastomer particles 108 and an adhesive is
placed in a mold, such as the mold 600. At block 804, one or more
removable inserts 608 may be positioned into the mold. Each of the
removable inserts is for forming a corresponding air chamber 110 in the
finished lower layer 106. At block 806, the removable inserts 608 are
covered with an additional layer of elastomer particles and the adhesive.

[0057] At decision block 808, a determination is made as to whether one or
more additional removable inserts 608 are to be inserted into the mold
and positioned within the elastomer particles 108. Thus, if it is
determined that one or more additional removable inserts 608 are to be
inserted into the mold ("yes" at decision block 808), the process 800 may
loop back to block 804, so that on the one or more additional removable
inserts 608 are inserted into the mold and covered with another layer of
elastomer particles and the adhesive.

[0058] However, if it is determined that no other removable inserts 608
are to be inserted into the mold ("no" at decision block 808), the
process 800 may proceed to block 810. At block 810, the adhesive is cured
to bind the elastomer particles 108. At block 812, the removable inserts
608 are removed from the mold. At block 814, the cured product in the
form of the lower layer 104 is removed from the mold.

[0059]FIG. 9 is a flow diagram illustrating an exemplary process for
forming a lower layer 104 of the composite floor tile that is reinforced
with one or more mesh sheets, in accordance with various embodiments. The
exemplary process 900 further illustrates block 702 of the process 700.
Further, at least some operations of the process 900 may be implemented
concurrently with the exemplary process 900 described above.

[0060] At block 902, a layer of elastomer particles and an adhesive is
placed in a mold, such as the mold 600. At block 904, a mesh sheet 112 is
positioned in on the layer of the elastomer particles 108. At block 906,
the mesh sheet 112 is covered with another layer of elastomer particles
and the adhesive.

[0061] At decision block 908, a determination is made as to whether
additional mesh sheets 112 are to be embedded with the elastomer
particles 108. In various embodiments, the number of mesh sheets 112 that
is to be embedded may be dependent on the desired thickness of the lower
layer 104. Thus, if it is determined that another mesh sheet 112 is to be
embedded ("yes" at decision block 908), the process 900 may loop back to
block 904, so that another mesh sheet 112 is positioned in place and
covered with another layer of elastomer particles and the adhesive.

[0062] However, if it is determined that no other mesh sheet 112 is to be
embedded ("no" at decision block 908), the process 900 may proceed to
block 910. At block 910, the adhesive is cured to bind the elastomer
particles 108. At block 912, the cured product in the form of the lower
layer 104 is removed from the mold.

[0063] The composite floor tile in accordance with the various embodiments
may reduce the spread of harmful containments and bacterial during usage,
while simultaneously protect personnel or properties from vibrations,
shocks, and falls. Further, the composite floor tiles in accordance with
the embodiments may provides an attractive upper surface that includes a
variety of pleasing fade-resistance color patterns, thereby enhancing the
aesthetics of the surrounding environments. As such, when compared to
conventional floor tiles with dyed colors, the composite floor in
accordance with the embodiments is more suitable for outdoor use than
conventional floor tiles. Nevertheless, the odorless characteristic of
the composite floor tile in accordance with the embodiments also makes it
especially suitable for indoor use as well.

[0064] Thus, the composite floor tile in accordance with the embodiments
has exceptional durability, comfort, resilience, density, and stability
characteristics. The composite floor tile also exhibits outstanding
performance and longevity in multiple environments, such as being
slip-resistance even when wet. The composite floor tile provides an
environmentally-friendly floor solution that is also easy to install and
maintain, and may be used to control the spread of bacteria, mildew, and
dust.

[0065] While embodiments of the invention have been illustrated and
described above, many changes can be made without departing from the
spirit and scope of the invention. Accordingly, the scope of the
invention is not limited by the disclosure of these embodiments. Instead,
the invention should be determined entirely by reference to the claims
that follow.